Multi-pass header assembly for a heat exchanger

ABSTRACT

The disclosed technology includes a header assembly for a water heating system heat exchanger. The header assembly can have an inlet, an outlet, a first compartment configured to receive a fluid from the inlet and direct the fluid to a first heat exchanger tube, a second compartment configured to receive the fluid from a second heat exchanger tube and direct the fluid to a third heat exchanger tube, and a third compartment configured to receive the fluid from a fourth heat exchanger tube and direct the fluid to the outlet.

FIELD OF TECHNOLOGY

The present disclosure relates generally to gas-fired water heating applications utilizing a heat exchanger, and, more particularly, to headers and header assemblies used to direct water through a heat exchanger of a water heating system.

BACKGROUND

Heat exchangers are used to facilitate heat transfer from a first fluid to a second fluid without mixing the two fluids. For example, heat can be transferred from a warmer first fluid to a cooler second fluid by passing the warmer first fluid across multiple heat exchanger tubes through which the second fluid is flowing. As the warmer first fluid passes across the surface of the multiple heat exchanger tubes, heat is transferred from the warmer first fluid through the heat exchanger tube to the second fluid. The heated second fluid can then be used as desired for the particular application.

In water heating applications, heat exchangers are commonly used to transfer heat from combustion gases created by burning or combusting a mixture of fuel and air at a burner to water passed through heat exchanger tubes. The resultant heated water is then directed to a point of use where the heated water can be used as desired.

To increase the heat transferred from the combustion gases to the water, some heat exchangers are configured with long heat exchanger tubes so that water in the heat exchanger tubes is able to be heated longer to achieve higher water temperatures. This configuration, however, can require an undesirably large heat exchanger to facilitate the heat transfer. Other water heating systems pass the combustion gases across the heat exchanger tubes multiple times to transfer as much heat from the combustion gases to the water as possible. This configuration, however, often causes moisture in the combustion gases to condense, requiring an additional drain system to remove the toxic condensate. Other heat exchangers are configured to pass the water through the heat exchanger tubes twice to increase the heat transferred to the water by using U-shaped heat exchanger tubes. Unfortunately, these types of heat exchangers often require as much space as single-pass heat exchangers.

To help monitor and control the heat transferred from the combustion gases to the water, many water heating control systems utilize various inputs from sensors (e.g., temperature sensors, flow sensors, water chemistry sensors, etc.) to ensure the water is heated properly and the water heating system is operating as expected. Unfortunately, incorporating the various sensors can often require additional components upstream or downstream of the heat exchanger to incorporate the various sensors. These additional components can add to the complexity and the overall size of the water heating system.

What is needed, therefore, is a compact heat exchanger assembly configured to direct the fluid through the heat exchanger tubes multiple times while incorporating various sensors to facilitate control of the heat exchanger. These and other problems are addressed by the technology disclosed herein.

SUMMARY

The disclosed technology relates generally to gas-fired water heating applications utilizing a heat exchanger, and, more particularly, to headers and header assemblies used to direct water through a heat exchanger of a water heating assembly.

The disclosed technology can include a header assembly for a water heating system heat exchanger. The header assembly can include a header body having an inlet, an outlet, a first compartment configured to receive a fluid from the inlet and direct the fluid to a first heat exchanger tube, a second compartment configured to receive the fluid from a second heat exchanger tube and to direct the fluid to a third heat exchanger tube, a third compartment configured to receive the fluid from a fourth heat exchanger tube and to direct the fluid to the outlet, and a removeable baffle configured to at least partially separate the first compartment, the second compartment, and the third compartment.

The removeable baffle can include first and second removeable baffles. The first removeable baffle can at least partially separate the first compartment and the third compartment while the second removeable baffle can at least partially separate the first compartment, the second compartment, and the third compartment, and direct the fluid from the inlet to the first heat exchanger tube.

The second removeable baffle can also include a curved planar surface configured to direct the fluid from the inlet to the first heat exchanger tube. The first removeable baffle can include a fluid bypass mechanism configured to direct an amount of the fluid proximate the inlet away from the first heat exchanger tube and toward the outlet. The first removeable baffle can also include a channel configured to receive and provide support to the second removeable baffle whereas the second removeable baffle can include a channel configured to receive a sealing material to create a seal between the second removeable baffle and a tube sheet of the heat exchanger.

The first heat exchanger tube can include a first number of heat exchanger tubes. Similarly, the second heat exchanger tube can include a second number of heat exchanger tubes, the third heat exchanger tube can include a third number of heat exchanger tubes, and the fourth heat exchanger tube can include a fourth number of heat exchanger tubes. The first number of heat exchanger tubes can be at least one greater than each of the second, third, and fourth numbers of heat exchanger tubes.

The header body can include one or more ports configured to receive a temperature sensor and/or a water chemistry sensor. Similarly, the header assembly can include an inlet temperature sensor configured to detect a temperature of the fluid proximate the inlet and/or an outlet temperature sensor configured to detect a temperature of the fluid proximate the outlet.

The header assembly can also include a governor assembly configured to control a flowrate of the fluid based on a temperature of the fluid. The header assembly can also include a sealing material configured to create a seal between the header and a tube sheet of the heat exchanger.

The disclosed technology can also include a header assembly for a water heating system heat exchanger. The header assembly can include a header body having an inlet, an outlet, an inlet compartment configured to receive a fluid from the inlet and direct the fluid to flow in a first direction, and an outlet compartment configured to receive the fluid flowing from a second direction and direct the fluid to the outlet. The second direction can be approximately opposite the first direction. The header assembly can also include one or more intermediate compartments, each of the one or more intermediate compartments can receive the fluid flowing from the second direction and direct the fluid to flow in the first direction.

The header assembly can also include a return header body having two or more return compartments. Each of the two or more return compartments can receive the fluid flowing from the first direction and direct the fluid to flow in the second direction. The header assembly can also include a plurality of heat exchanger tubes fluidly connecting each of the two or more return compartments to the inlet compartment, the outlet compartment, and/or one or more of the intermediate compartments.

The disclosed technology can also include a heat exchanger assembly for a water heating system. The heat exchanger assembly can include a plurality of heat exchanger tubes configured to transfer heat from a first fluid to a second fluid and a first header in fluid communication with the plurality of heat exchanger tubes. The first header can include an inlet, an outlet, and a first header baffle configured to at least partially separate an interior of the first header into a first compartment, a second compartment, and a third compartment. The heat exchange assembly can additionally include a second header in fluid communication with the plurality of heat exchanger tubes. The second header can include a second header baffle configured to at least partially separate an interior of the second header into a first return compartment and a second return compartment. The heat exchanger assembly can direct a flow of the second fluid from the inlet and sequentially through the first compartment, through a first heat exchanger tube of the plurality of heat exchanger tubes, through the first return compartment, through a second heat exchanger tube of the plurality of heat exchanger tubes, through the second compartment, through a third heat exchanger tube of the plurality of heat exchanger tubes, through the second return compartment, through a fourth heat exchanger tube of the plurality of heat exchanger tubes, and through the third compartment to the outlet.

The first header can further include an inlet temperature sensor configured to detect a temperature of the fluid proximate the inlet and/or an outlet temperature sensor configured to detect a temperature of the fluid proximate the outlet.

The first header baffle can include a first removeable baffle portion and a second removeable baffle portion. The first removeable baffle portion can be configured to at least partially separate the first compartment and the third compartment and the second removeable baffle portion can be configured to at least partially separate the first compartment, the second compartment, and the third compartment. The first removeable baffle can also include a fluid bypass mechanism configured to direct an amount of the second fluid proximate the inlet toward the outlet.

The first header can additionally include a plurality of support ribs configured to provide support to the first removeable baffle portion and the second removeable baffle portion while the second header can include a protrusion on an inside surface of the second header configured to direct the second fluid toward the plurality of heat exchanger tubes.

Additional features, functionalities, and applications of the disclosed technology are discussed herein in more detail.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate multiple examples of the presently disclosed subject matter and serve to explain the principles of the presently disclosed subject matter. The drawings are not intended to limit the scope of the presently disclosed subject matter in any manner.

FIG. 1 illustrates a top isometric view of an example heat exchanger assembly for a water heating system, in accordance with the disclosed technology.

FIG. 2 illustrates an exploded view of an example heat exchanger assembly for a water heating system, in accordance with the disclosed technology.

FIGS. 3A and 3B illustrate a view of an inner surface of two example headers for a heat exchanger assembly with the relative locations of various heat exchanger tubes being shown, in accordance with the disclosed technology.

FIG. 4 illustrates an exploded view of an example header for a heat exchanger assembly, in accordance with the disclosed technology.

FIG. 5A illustrates a front top isometric view of an example header for a heat exchanger assembly, in accordance with the disclosed technology.

FIG. 5B illustrates a front bottom isometric view of an example header for a heat exchanger assembly, in accordance with the disclosed technology.

FIG. 5C illustrates a rear top isometric view of an example header for a heat exchanger assembly, in accordance with the disclosed technology.

FIG. 5D illustrates a rear bottom isometric view of an example header for a heat exchanger assembly, in accordance with the disclosed technology.

FIG. 6A illustrates a view of an inner surface of an example header assembly for a heat exchanger assembly in an assembled state, in accordance with the disclosed technology.

FIG. 6B illustrates a view of an inner surface of an example header for a heat exchanger assembly, in accordance with the disclosed technology.

FIG. 7 illustrates an isometric cross-sectional view of the example header assembly shown in FIG. 6A taken along line 1-1, in accordance with the disclosed technology.

FIG. 8 illustrates an exploded view of an example header assembly for a heat exchanger assembly, in accordance with the disclosed technology.

FIG. 9A illustrates an exploded view of another example header assembly for a heat exchanger assembly, in accordance with the disclosed technology.

FIG. 9B illustrates a view of an inner surface of another example header for a heat exchanger assembly, in accordance with the disclosed technology.

DETAILED DESCRIPTION

The present disclosure relates generally to gas-fired water heating applications utilizing a heat exchanger, and, more particularly, to headers used to direct water through a heat exchanger of a water heating system. The disclosed technology, for example, can include one or more headers (e.g., two headers) that can direct water through a heat exchanger multiple times. The first and second headers, for example, can have multiple compartments for receiving and directing water through heat exchanger tubes such that the water is passed through the heat exchanger tubes multiple times before exiting the heat exchanger. In this way, the disclosed technology can be configured to effectively heat water within a small space, which can help decrease the size of the heat exchanger. The headers can also be configured to incorporate various sensors that can be used to control the water heating system. The disclosed technology can be used with any gas-fired system having a heat exchanger used to heat water, including residential water heaters, commercial water heaters, and pool heaters, but is not so limited.

Although certain examples of the disclosed technology are explained in detail, it is to be understood that other examples, embodiments, and implementations of the disclosed technology are contemplated. Accordingly, it is not intended that the disclosed technology is limited in its scope to the details of construction and arrangement of components set forth in the following description or illustrated in the drawings. The disclosed technology can be implemented in a variety of examples and can be practiced or carried out in various ways. In particular, the presently disclosed subject matter is described in the context of being a header for a heat exchanger used in a water heating system. The present disclosure, however, is not so limited, and can be applicable in other heat exchangers. The present disclosure, for example and not limitation, can include heat exchangers configured to transfer heat between fluids other than combustion gases and water. As will be appreciated, the disclosed technology can be used in many other heat exchanger applications where heat is transferred from one fluid to another fluid. Such implementations and applications are contemplated within the scope of the present disclosure. Accordingly, when the present disclosure is described in the context of being a header for a heat exchanger used in gas-fired water heaters, it will be understood that other implementations can take the place of those referred to. Furthermore, when reference is made to water being the fluid in the heat exchanger, it will be understood that other fluids can take the place of water.

It should also be noted that, as used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. References to a composition containing “a” constituent is intended to include other constituents in addition to the one named.

Also, in describing the examples, terminology will be resorted to for the sake of clarity. It is intended that each term contemplates its broadest meaning as understood by those skilled in the art and includes all technical equivalents which operate in a similar manner to accomplish a similar purpose.

Herein, the use of terms such as “having,” “has,” “including,” or “includes” are open-ended and are intended to have the same meaning as terms such as “comprising” or “comprises” and not preclude the presence of other structure, material, or acts. Similarly, though the use of terms such as “can” or “may” are intended to be open-ended and to reflect that structure, material, or acts are not necessary, the failure to use such terms is not intended to reflect that structure, material, or acts are essential. To the extent that structure, material, or acts are presently considered to be essential, they are identified as such.

The components described hereinafter as making up various elements of the disclosed technology are intended to be illustrative and not restrictive. Many suitable components that would perform the same or similar functions as the components described herein are intended to be embraced within the scope of the disclosed technology. Such other components not described herein can include, but are not limited to, for example, similar components that are developed after development of the presently disclosed subject matter.

Referring now to the drawings, in which like numerals represent like elements, examples of the present disclosure are herein described. As will be described in greater detail, the present disclosure includes a header for a heat exchanger used in gas-fired water heaters.

As shown in FIG. 1 and FIG. 2, a gas-fired water heating system can include a heat exchanger assembly 100 having a heat exchanger tube bundle 200, an inlet/outlet header 300, and a return header 400. As will become apparent throughout this disclosure, the heat exchanger assembly 100 can be configured to pass water (or another fluid) through the length of the tube bundle 200 multiple times to increase the amount of heat transferred and to maintain a compact heat exchanger design.

The tube bundle 200 can include heat exchanger tubes 202 configured to transfer heat from a first fluid to a second fluid (e.g., from a combustion gas to water). As described in greater detail herein, the inlet/outlet header 300 and the return header 400 can be configured to direct the water through the heat exchanger tubes 202, obviating the need for tubes having bends (e.g., U-tubes, etc.). Accordingly, the heat exchanger tubes 202 can include substantially straight tubes which can simply and decrease the cost of manufacturing. The heat exchanger tubes 202 can be any suitable type of heat exchanger tube for the application. For example, the heat exchanger tubes 202 can be or include heat exchanger tubes 202 made from low carbon steel, Admiralty, copper, copper-nickel, stainless steel, Hastelloy, Inconel, titanium, or any other suitable material for the application. Furthermore, the heat exchanger tubes 202 can have fins affixed to an outer surface of the heat exchanger tube 202 to help facilitate heat transfer between the first and second fluids.

The tube bundle 200 can also include tube sheets 204 configured to keep the heat exchanger tubes 202 in position and to attach the inlet/outlet header 300 and the return header 400 to the tube bundle 200. The inlet/outlet header 300 and the return header 400 can be fastened to the tube bundle 200 by fasteners 208. The fasteners 208 can include any combination of any type of fastening method or device, including, for example, crimping, welding, soldering, brazing, one or more adhesives, tape, screws, bolts, nuts, washers, threaded rods, pins, clips, clamps, rivets, or the like. Furthermore, the tube bundle 200 can include one or more heat exchanger baffles 206 configured to direct a flow of the combustion gases, or other fluid, as it passes through the heat exchanger tube bundle 200.

FIGS. 3A and 3B illustrate a view of an inner surface of two headers for a heat exchanger assembly with example locations of heat exchanger tubes depicted in relation to the headers, in accordance with the disclosed technology. In particular, FIG. 3A illustrates a rear view of the inlet/outlet header 300, whereas FIG. 3B illustrates a rear view of the return header 400. As can be seen in FIGS. 3A and 3B, the inlet/outlet header 300 and the return header 400 can be configured such that the heat exchanger tubes 202 align with various compartments or sections of the respective headers 300, 400. For example, and as illustrated in FIG. 3A, the inlet/outlet header 300 can be configured such that four groupings of heat exchanger tubes 202 align with three separate compartments of the inlet/outlet header 300. For example, a first group 1 of heat exchanger tubes 202 (denoted with a “1” in FIG. 3A) can align with a first compartment 380 nearest the inlet 304 of the inlet/outlet header 300, a second group 2 and a third group 3 of heat exchanger tubes 202 (respectively denoted with a “2” and a “3” in FIG. 3A) can align with a second compartment 382 of the inlet/outlet header 300, and a fourth group 4 of heat exchanger tubes 202 (denoted with a “4” in FIG. 3A) can align with a third compartment 384 of the inlet/outlet header 300, which is nearest the outlet 306 of the inlet/outlet header 300.

Similarly, the return header 400 can be configured such that the four groupings of heat exchanger tubes 202 can align with two separate compartments of the return header 400. The four groupings of heat exchanger tubes 202 can be the same four groupings of heat exchanger tubes 202 discussed in relation to the inlet/outlet header 300. For example, the first group 1 of heat exchanger tubes 202 discussed in relation to the inlet/outlet header 300 can be the same first group 1 of heat exchanger tubes 202 discussed in relation to the return header 400, and so forth. As depicted in FIG. 3B, the first group 1 and the second group 2 of heat exchanger tubes 202 (respectively denoted with a “1” and a “2” in FIG. 3B) can align with a first return compartment 480 of the return header 400 and the third group 3 and the fourth group 4 of heat exchanger tubes 202 (respectively denoted with a “3” and a “4” in FIG. 3B) can align with a second return compartment 482 of the return header 400.

As will be appreciated, the example inlet/outlet header 300 and the example return header 400 just described can be configured to pass water through the heat exchanger tubes 202 in thermal communication with the combustion gas at least a total of four times. By doing so, the heat exchanger assembly 100 can be configured to efficiently, and compactly, transfer heat from a combustion gas passing across an outer surface of the heat exchanger tubes 202 to the water passing through the heat exchanger tubes 202. This example, however, should not be construed as limiting as the disclosed technology described herein can apply to heat exchanger assemblies 100 configured to pass water through the heat exchanger tubes 202 more or less times than the four times just described.

The example inlet/outlet header 300 and return header 400 can be configured to pass the water through the heat exchanger tubes 202 according to the following example. The inlet/outlet header 300 can receive water at the first compartment 380 through an inlet 304. The first compartment 380 of the inlet/outlet header 300 can direct water to flow through a first group 1 of heat exchanger tubes 202 in a first direction (e.g., from the inlet/outlet header 300 toward the return header 400) to the return header 400 at the other end of the first group 1 of heat exchanger tubes 202. As an example, the first group 1 of heat exchanger tubes 202 is shown as comprising five heat exchanger tubes 202. The first return compartment 480 of the return header 400 can be configured to receive water from the first group 1 of heat exchanger tubes 202 and redirect water to flow through the second group 2 of heat exchanger tubes 202 in a second direction (e.g., from the return header 400 to the inlet/outlet header 300). The second direction can be substantially opposite the first direction. As an example, the second group 2 of heat exchanger tubes 202 is shown as comprising four heat exchanger tubes 202. Water can flow through the second group 2 of heat exchanger tubes 202 in the second direction to the second compartment 382 of the inlet/outlet header 300. As will be appreciated, the second compartment 382, as shown, can function as a return compartment similar to the function provided by the first and second return compartments 480, 482 of the return header 400. That is to say, the second compartment 382 of the inlet/outlet header 300 can receive water flowing through the second group 2 of heat exchanger tubes 202 in the second direction and redirect water to flow through the third group 3 of heat exchanger tubes 202 in the first direction. As an example, the third group 3 of heat exchanger tubes is shown as comprising four heat exchanger tubes 202. Water can flow through the third group 3 of heat exchanger tubes 202 in the first direction to enter the return header 400 at the second return compartment 482. The second return compartment 482 of the return header 400 can receive water flowing through the third group 3 of heat exchanger tubes 202 in the first direction and redirect water to flow through the fourth group 4 of heat exchanger tubes 202 in the second direction. As an example, the fourth group 4 of the heat exchanger tubes 202 is shown as comprising four heat exchanger tubes 202. Water can flow through the fourth group 4 of heat exchanger tubes 202 in the second direction to a third compartment 384 of the inlet/outlet header 300 and out of the inlet/outlet header 300 via an outlet (e.g., outlet 306, as shown in FIG. 4). As will be appreciated, the example just described can be adapted for applications intended to pass water through heat exchanger tubes 202 more or less than four times.

As will be appreciated, the flow rate of water along a given pass can be controlled by the number of heat exchanger tubes 202 provided between corresponding compartments of the inlet/outlet header 300 and the return header 400. For example, FIGS. 3A and 3B depict different numbers of heat exchanger tubes 202 corresponding to different compartments of the inlet/outlet header 300 and the return header 400. As a specific example, because the first group 1 of heat exchanger tubes 202 can comprise five heat exchanger tubes while the second group 2, the third group 3, and the fourth group 4 of the heat exchanger tubes 202 can each comprise only four heat 202 exchanger tubes, the water can pass more slowly through the heat exchanger tubes 202 when the water first enters the heat exchanger assembly 100. In this way, the water can receive more heat on the first pass than the other passes through the heat exchanger assembly 100. This can help to ensure the water temperature doesn't exceed a threshold temperature by the time the water passes through the fourth group 4 of heat exchanger tubes 202. The threshold temperature can be a predetermined temperature of the water that could cause damage to the heat exchanger tubes 202 or output water having a temperature that could injure an end user.

To further ensure that water flowing through any of the groups of heat exchanger tubes 202 does not exceed a threshold temperature, the first compartment 380, the second compartment 382, and third compartment 384 of the inlet/outlet header 300 as well as the first return compartment 480 and the second return compartment 482 of the return header 400 can each be sized such that the water flowing through the heat exchanger assembly 100 progressively flows faster through the heat exchanger as the water moves from inlet 302 to the outlet 304. For example, the respective volumes of each compartment can get progressively smaller as water is directed through the inlet/outlet header 300 and the return header 400. Thus, the respective volume of the first compartment 380 can be greater than the respective volume of the second compartment 382 which can be greater than the respective volume of the third compartment 384 with respect to the number of heat exchanger tubes present at each compartment. Similarly, the respective volume of the first return compartment 480 can be greater than the respective volume of the second return compartment of the return header 400.

The example inlet/outlet header 300 in FIG. 3A is illustrated as including three separate compartments 380, 382, 384, and the return header 400 in FIG. 3B is illustrated as including two separate compartments 480, 482. The disclosed technology, however, is not so limited. Indeed, the inlet/outlet header 300 can include as few as two compartments: an input compartment configured to receive water from the inlet of the inlet/outlet header 300 and an output compartment configured to output water to the outlet of the inlet/outlet header 300. Optionally, the inlet/outlet header 300 can include one or more intermediate compartments configured to change the direction of water flow (i.e., receive water flowing from the return header 400 and redirect the water to flow back toward the return header 400). The return header 400 can include a number of compartments that is one less than the number of compartments of the inlet/outlet header 300. For example, the return header 400 can include as few as one compartment. The compartment(s) of the return header 400 can be configured to change the direction of water flow (i.e., receive water flowing from the inlet/outlet header 300 and redirect the water to flow back toward the inlet/outlet header 300).

The inlet/outlet header 300 and the return header 400 can include additional features and components, which can improve the function and performance of the heat exchanger assembly 100, as discussed herein. The inlet/outlet header 300 can have an inlet/outlet header body 302 having an inlet 304 and an outlet 306. The inlet 302 can be adapted to receive water from a water source, and the outlet 306 can be adapted to direct water from the inlet/outlet header 300 to a point of use. As will be appreciated by those of skill in the art, the inlet/outlet header body 302 having the inlet 304 and outlet 306 on the same side of the heat exchanger can make it easier for the heat exchanger assembly 100 to be installed in currently-existing systems and/or for the heat exchanger assembly 100 to be serviced.

The inlet/outlet header body 302 can have a governor aperture 308 configured to receive a governor assembly 350. The governor aperture can be located proximate the outlet such that the governor assembly 350 can be configured to control the flow of the fluid through the heat exchanger assembly 100. As will be appreciated by those of skill in the art, the governor assembly 350 can be configured to control the flow of the water through the heat exchanger assembly 100 to ensure the temperature of the water exiting through the outlet is maintained based on a predetermined temperature. The governor assembly 350 can be any type of governor assembly suitable for the application. For example, the governor assembly 350 can be a mechanically actuated governor assembly or an electro-mechanically controlled governor assembly 350.

The inlet/outlet header body 302 can have an inlet temperature sensor aperture 310 (as illustrated in FIG. 5B) and an outlet temperature sensor aperture 312 (also illustrated in FIG. 5G). The inlet temperature aperture 310 can be configured to receive an inlet temperature sensor 352 that can be configured to detect a temperature of the water entering the inlet/outlet header body 302. Similarly, the outlet temperature aperture 312 can be configured to receive an outlet temperature sensor 354 configured to detect a temperature of the water exiting the inlet/outlet header body 302.

The inlet temperature sensor 352 and the outlet temperature sensor 354 can be any type of temperature sensor suitable for the application. For example, and not limitation, the inlet temperature sensor 352 and the outlet temperature sensor 354 can be or include a thermocouple, a resistor temperature detector (RTD), a thermistor, an infrared sensor, a semiconductor, or any other suitable type of temperature sensor for the application. As will be appreciated, the inlet temperature sensor 352 and the outlet temperature sensor 354 can both be configured to output data to a controller in communication with the inlet temperature sensor 352 and the outlet temperature sensor 354.

The inlet/outlet header body 302 can have a chemistry sensor aperture 314 (as illustrated in FIG. 5A) configured to receive a chemistry sensor 356. The chemistry sensor 360 can be configured to detect chemical properties of the water in the heat exchanger assembly 100. For example, the chemistry sensor 360 can be a chlorine sensor (e.g., a ion selective potentiostatic membrane sensor, an open system amperometric chlorine cell, or any other suitable chlorine sensor), a Total Organic Carbon (TOC) sensor, a Total Dissolved Solids (TDS) sensor, a turbidity sensor, a conductivity sensor, a pH sensor, an Oxygen-Reduction Potential (ORP) sensor, or any other suitable sensor for the application.

The inlet/outlet header body 302 can have a first high/low temperature sensor mount 316 and a second high/low temperature sensor mount 317 (as illustrated in FIG. 5B). The first high/low temperature sensor mount 316 can be configured to receive a first high/low temperature sensor mount 364 and the second high/low temperature sensor mount 317 can be configured to receive a second high/low temperature sensor 364. As will be appreciated, the first high/low temperature sensor 362 and the second high/low temperature sensor 364 can both be configured to detect a temperature of the water in the heat exchanger assembly 100 and output data to a controller in communication with the first high/low temperature sensor 362 and the second high/low temperature sensor 364. The first high/low temperature sensor 362 and the second high/low temperature sensor 364 can both be configured to detect a temperature of the water in the heat exchanger assembly 100 by detecting a surface temperature of the inlet/outlet header body 302 or by detecting a temperature of the water directly. The first high/low temperature sensor 362 and the second high/low temperature sensor 364 can, for example, can be or include a thermocouple, a resistor temperature detector (RTD), a thermistor, an infrared sensor, a semiconductor, or any other suitable type of temperature sensor for the application.

The inlet/outlet header body 302 can include access points for maintaining or servicing the inlet/outlet header 300. For example, the inlet/outlet header body 302 can have one or more service apertures 318 (as illustrated in FIG. 5A) and one or more drain apertures 319 (as illustrated in FIG. 5B). The service apertures 318 can be configured to receive a service plug 370 and the drain apertures 319 can be configured to receive a drain plug 368. As will be appreciated, the service plug 370 and the drain plug 368 can each be configured to create a seal at an interface of the inlet/outlet header body 302 such that no water is allowed to escape the inlet/outlet header body 302. The service apertures 318 can be configured to facilitate a user, technician, or other individual to access the internals of the inlet/outlet header body 302 without needing to entirely remove the inlet/outlet header body 302 from the heat exchanger assembly 100. Furthermore, the drain apertures 319 can be configured for a user, technician, or other individual to drain the water from the heat exchanger assembly 100.

The inlet/outlet header body 302 can include bolt mounting apertures 320 configured to align with corresponding apertures on the tube sheet 204 such that the inlet/outlet header body 302 can be mounted and secured to the tube sheet 204 with the fasteners 208. The bolt mounting apertures 320 can be located around the outer perimeter of the inlet/outlet header body 302 such that a seal can be adequately formed between the inlet/outlet header body 302 and the tube sheet 204 when fastened. As will be appreciated, the bolt mounting apertures 320 and fasteners 208 are offered merely as an example method of securing the inlet/outlet header body 302 to the tube sheet 204 and other methods of fastening or securing the inlet/outlet header body 302 to the tube sheet 204 can be used. For example, and not limitation, the inlet/outlet header body 302 can be fastened or secured to the tube sheet 204 via a weld, adhesives, clamps, press fit, brazed, bonded, or any other suitable method for the application.

The inlet/outlet header body 302 can have a gasket channel 325 configured to receive a gasket to help prevent leakage at an interface between the inlet/outlet header body 302 and the tube sheet 204. The gasket can be any type of sealing material suitable for the application. For example, and not limitation, the sealing material can be made from or include silicone rubber, natural rubber, nitrile, neoprene sponge, neoprene rubber, cork, asbestos, FKM fluoroelastomer rubber, compressed non-asbestos fiber (CNAF), polytetrafluoroethylene (PTFE), soft iron, low carbon steel, stainless steel, monel, Inconel, composite materials, or any other suitable material for the application.

As will be discussed in greater detail herein, and as illustrated in FIG. 4, the inlet/outlet header 300 can include a bypass mechanism baffle 330 and a curved baffle 340. The bypass mechanism baffle 330 and the curved baffle 340 can be configured to separate the interior of the inlet/outlet baffle 300 into the three compartments discussed previously. As illustrated in FIGS. 5C and 5D, when the bypass mechanism baffle 330 and the curved baffle 340 are installed, the curved baffle 340 can be substantially flush with a back surface of the inlet/outlet header body 302. In this way, the curved baffle 340 can similarly form a seal between the curved baffle 340 and the tube sheet 204 to create the three separate compartments. To help ensure separation between the three compartments, the inlet/outlet header 300 can include a gasket 348 (as illustrated in FIGS. 7 and 8) that can be made from or include the same or similar gasket material just described.

The bypass mechanism baffle 330, as will be described in greater detail herein, can be configured to receive a bypass mechanism 366. The bypass mechanism 366 can be configured to direct a flow of water from the inlet 304 toward the outlet 306 depending on the conditions of the system and the desired output. For example, the bypass mechanism 366 can be configured to open based on a pressure at the bypass mechanism 366 to redirect the water from the inlet 304 toward the outlet 306 to help ensure the pressure in the heat exchanger assembly 100 remains less than or equal to a threshold pressure. Alternatively, or in addition, the bypass mechanism 366 can be configured to open based on a temperature of the water at the bypass mechanism 366 to redirect the water from the inlet 304 toward the outlet 306 to help ensure the temperature of the water exiting the outlet 306 remains less than or equal to a threshold temperature.

FIG. 6A illustrates a view of an inner surface of an example inlet/outlet header 300 having the bypass mechanism baffle 330, curved baffle 340, and gasket 348 installed. FIG. 6B, on the other hand, illustrates a view of an inner surface of an example inlet/outlet header 300 having the bypass mechanism baffle 330, curved baffle 340, and gasket 348 removed.

As will be appreciated, the bypass mechanism baffle 330 and/or the curved baffle 340 can experience forces caused by the pressure of the water flowing through the inlet/outlet header 300. To help counteract the forces exerted on the bypass mechanism baffle 330 and/or the curved baffle 340, and as illustrated in FIG. 6B, the inlet/outlet header body 302 can have a support channel 321, side support ridges 322, a side support channel 323, and bottom support ridges 324 that are each configured to receive and/or support the bypass mechanism baffle 330 and/or the curved baffle 340. The support channel 321, side support ridges 322, side support channel 323, and bottom support ridges 324 can each provide support by preventing the bypass mechanism baffle 330 and/or the curved baffle 340 from moving or deflecting excessively while the heat exchanger assembly 100 is in use. Additionally, the support channel 321, side support ridges 322, side support channel 323, and bottom support ridges 324 can each help to create a seal between the inlet/outlet header body 302, the bypass mechanism baffle 330 and the curved baffle 340.

The support channel 321 and the side support channel 323 can each be formed by forming two or more parallel ridges protruding from the inside surface of the inlet/outlet header body 302. Alternatively, or in addition, the support channel 321 and the side support channel 323 can be formed by forming a depression in the wall of the inlet/outlet header body 302. The support channel 321 can be configured to provide support to the bypass mechanism baffle 330 when the heat exchanger assembly 100 is in use and the side support channel 323 can be configured to provide support to the curved baffle 340 when the heat exchanger assembly 100 is in use. As an example, the support channel 321 can help to ensure the bypass mechanism baffle 330 does not move or deflect excessively when the heat exchanger assembly 100 is in use. Similarly, the side support channel 323 can help to ensure the curved baffle 340 does not move or deflect excessively when the heat exchanger assembly 100 is in use.

The side support ridges 322 and the bottom support ridges 324 can each be formed by forming protrusions from the inside surface of the inlet/outlet header body 324. Alternatively, or in addition, the side support ridges 322 and the bottom support ridges 324 can be formed by forming a depression in the wall of the inlet/outlet header body 302. The side support ridges 322 can be configured to provide support to both the bypass mechanism baffle 330 and the curved baffle 340 when the heat exchanger assembly 100 is in use and the bottom support ridges 324 can be configured to provide support to the bypass mechanism baffle 330 when the heat exchanger assembly 100 is in use. As an example, the side support ridges 322 can help to ensure the bypass mechanism baffle 330 and the curved baffle 340 do not move or deflect excessively when the heat exchanger assembly 100 is in use. Similarly, the bottom support ridges 324 can help to ensure the bypass mechanism baffle 330 does not move or deflect excessively when the heat exchanger assembly 100 is in use.

FIG. 7 illustrates an isometric cross-sectional view of the example header assembly cut along section line 1-1 depicted in FIG. 6A, in accordance with the disclosed technology. As can be observed in FIG. 7, the inlet/outlet header body 302 can be configured to receive and provide support to the bypass mechanism baffle 330 at the support channel 321 and the side support ridges 322. Similarly, the inlet/outlet header body 302 can be configured to receive and provide support to the curved baffle 340 at the side support channel 323 (not shown in FIG. 7) and the side support ridges 322.

As can be observed in FIG. 7, the inlet/outlet header 300 can be configured to direct water entering the inlet 304 toward the bypass mechanism baffle 330, toward the curved baffle 340, and then toward the first group 1 of heat exchanger tubes 202 (not illustrated in FIG. 7). Furthermore, as will be appreciated, the curved baffle 340 can be configured to facilitate flow of water directed toward the first group 1 of heat exchanger tubes 202. For example, the curved profile 342 of the curved baffle 340 can help to ensure water flows toward the first group 1 of heat exchanger tubes rather than being directed back toward the inlet 304 or toward the walls of the inlet/outlet header body 302.

FIG. 8 illustrates an exploded view of the inlet/outlet header 300 illustrating the inlet/outlet header body 302, the bypass mechanism baffle 330, the curved baffle 340, and the gasket 348. As previously described, the bypass mechanism baffle 330 and the curved baffle 340 can be assembled with the inlet/outlet header body 302 to form the inlet/outlet header 300 having three compartments.

The bypass mechanism baffle 330 can have a curved baffle support channel 332 that is configured to receive and support the curved baffle 330. The curved baffle support channel 332 can be formed by forming two or more parallel ridges protruding a side surface of the bypass mechanism baffle 330. The curved baffle support channel 332 can be configured to provide support to the curved baffle 340 when the heat exchanger assembly 100 is in use. As an example, the curved baffle support channel 332 can help to ensure the curved baffle 340 does not move or deflect excessively when the heat exchanger assembly 100 is in use.

The bypass mechanism baffle 330 can also have a bypass mechanism aperture 333 configured to receive and support the bypass mechanism 366 previously described. The bypass mechanism aperture 333 can include holes whereby water entering the inlet/outlet header body 302 can be directed toward the outlet 306.

The bypass mechanism baffle 330 can further include a governor valve aperture 334 configured to receive and support the governor valve assembly 350 previously described. The governor valve aperture 334 can be sized such that the governor valve assembly 350 can adequately restrict the flow of water flowing from the fourth group 4 of heat exchanger tubes 202 toward the outlet 306. Furthermore, the governor valve aperture 334 can incorporate a smoothed or rounded edge to help facilitate the flow of water through the governor valve aperture 334.

The governor valve assembly 350 can include one or more flow orifices 335 configured to allow water to flow from the tube bundle 200 toward the outlet 306, even when the governor valve assembly 350 is entirely closed. In this way, water can flow toward the outlet 306 solely through the flow orifices 335 until the governor valve assembly 350 opens when the water reaches a predetermined temperature.

The bypass mechanism baffle 330 can further include side support cutouts 336 that are positioned and sized to interface with the side support ridges 322 of the inlet/outlet header body 302. The side support cutouts 336 can ensure the bypass mechanism baffle 330 adequately contacts the side support ridges 322 such that the side support ridges 322 can help to support the bypass mechanism baffle 330 and create a seal between the bypass mechanism baffle 330 and the inlet/outlet header body 302.

Similarly, the bypass mechanism baffle 330 can further include bottom support cutouts 338 that are positioned and sized to interface with the bottom support ridges 324 of the inlet/outlet header body 302. The bottom support cutouts 338 can ensure the bypass mechanism baffle 330 adequately contacts the bottom support ridges 324 such that the bottom support cutouts 338 can help to support the bypass mechanism baffle 330 and create a seal between the bypass mechanism baffle 330 and the inlet/outlet header body 302.

The curved baffle 340 can include a curved profile 342. As previously described, the curved profile 342 can help to facilitate a flow of water from the inlet 304 toward the first group 1 of heat exchanger tubes 202.

The curved baffle 340 can include a sidewall 344 configured to separate the first compartment 380 and the third compartment 384 from the second compartment 382. Furthermore, the sidewall 344 can be configured to be inserted into, or otherwise interface with, the side support channel 323 to ensure the curved baffle 340 remains in place and is prevented from deflecting excessively when the heat exchanger assembly 100 is in use.

The curved baffle 340 can further include a curved baffle gasket channel 346 configured to receive, or otherwise interface with, a curved baffle gasket 348 to help prevent leakage at an interface between the curved baffle 340 and the tube sheet 204.

FIG. 9A illustrates an exploded view of the return header 400 in accordance with an example of the disclosed technology. The return header 400 can include a return header body 402, a return header gasket 420, and a return header drain plug 430. The return header gasket 420 can be or include the same type of gasket material previously described. Furthermore, the return header drain plug 430 can perform the same function of the drain plug 368 previously described.

FIG. 9B illustrates a view of an inner surface of the return header body 402 in accordance with an example of the disclosed technology. The return header body 402 can include a separation baffle 404 configured to separate the interior of the return header body 402 into the first return compartment 480 and the second return compartment 482 previously described. The separation baffle 404 can be configured to be removeable or permanently installed. The return header body 402 and the return header separation baffle 404 can both include a return header gasket channel 406 configured to receive the return header gasket 420. The return header gasket 420 can help to create a seal between the return header body 402 and the tube sheet 402 when the return header body 402 is mounted to the tube sheet 204.

To help facilitate mounting of the return header body 402 to the tube sheet 204, the return header body can include mounting bolt holes 410 configured to receive fasteners 208. The mounting bolt holes 410 can perform the same function as the previously described in relation to the mounting bolt holes 320 of the inlet/outlet header body 302. Furthermore, the return header body 402 can be configured to be affixed to the tube sheet 204 by any of the methods described in relation to the inlet/outlet header body 302.

The return header body 402 can include a return header drain plug aperture 408 that can be sized to receive the return header drain plug 430. The return header drain plug aperture 408 and return header drain plug 430 can perform the same function previously described in relation to the drain aperture 319 and the drain plug 368. For example, the return header drain plug aperture 408 can be used to drain the heat exchanger assembly 100.

The return header body 402 can further include flow distribution ridges 412 configured to enhance the flow characteristics of the water flowing through the return header body 402 when in use. The flow distribution ridges 412 can be protrusions extending inwardly into the return header body 402 to help direct the flow of the water toward the heat exchanger tubes 202. As an example the flow distribution ridges 412 can be located in the first return compartment 480 proximate the second group 2 of heat exchanger tubes 202 such that water flowing from the first group 1 of heat exchanger tubes 202 into the first return compartment 480 can be directed toward the second group 2 of heat exchanger tubes 202. By directing the water from the first return compartment 480 and toward the second group 2 of heat exchangers 202, the flow distribution ridges 412 can help to ensure that the heat exchanger tubes 202 have adequate flow of water and are prevented from overheating. As will be appreciated, the flow distribution ridges 412 can comprise a single flow distribution ridge 412 or many flow distribution ridges 412. Furthermore, the location of the flow distribution ridges 412 can be varied depending on the particular application and the desired flow characteristics of the heat exchanger assembly 100.

While the present disclosure has been described in connection with a plurality of exemplary aspects, as illustrated in the various figures and discussed above, it is understood that other similar aspects can be used, or modifications and additions can be made to the described aspects for performing the same function of the present disclosure without deviating therefrom. For example, in various aspects of the disclosure, methods and compositions were described according to aspects of the presently disclosed subject matter. But other equivalent methods or composition to these described aspects are also contemplated by the teachings herein. Therefore, the present disclosure should not be limited to any single aspect, but rather construed in breadth and scope in accordance with the appended claims. 

What is claimed is:
 1. A header assembly for a water heating system heat exchanger, the header assembly comprising: a header body comprising: an inlet; an outlet; a first compartment configured to receive a fluid from the inlet and direct the fluid to a first heat exchanger tube; a second compartment configured to receive the fluid from a second heat exchanger tube and direct the fluid to a third heat exchanger tube; a third compartment configured to receive the fluid from a fourth heat exchanger tube and direct the fluid to the outlet; and a removeable baffle configured to, at least partially separate the first compartment, the second compartment, and the third compartment.
 2. The header assembly of claim 1, wherein: the removeable baffle comprises a first removeable baffle and a second removeable baffle, the first removeable baffle is configured to at least partially separate the first compartment and the third compartment, and the second removeable baffle is configured to (i) at least partially separate the first compartment, the second compartment, and the third compartment, and (ii) direct the fluid from the inlet to the first heat exchanger tube.
 3. The header assembly of claim 2, wherein the second removeable baffle further comprises a curved planar surface configured to direct the fluid from the inlet to the first heat exchanger tube.
 4. The header assembly of claim 2, wherein the first removeable baffle further comprises a fluid bypass mechanism configured to direct an amount of the fluid proximate the inlet away from the first heat exchanger tube and toward the outlet.
 5. The header assembly of claim 2, wherein the first removeable baffle further comprises a channel configured to receive and provide support to the second removeable baffle.
 6. The header assembly of claim 2, wherein the second removeable baffle further comprises a channel configured to receive a sealing material configured to create a seal between the second removeable baffle and a tube sheet of the heat exchanger.
 7. The header assembly of claim 1, wherein: the first heat exchanger tube comprises a first number of heat exchanger tubes, the second heat exchanger tube comprises a second number of heat exchanger tubes, the third heat exchanger tube comprises a third number of heat exchanger tubes, the fourth heat exchanger tube comprises a fourth number of heat exchanger tubes, and the first number of heat exchanger tubes is at least one greater than each of the second, third, and fourth numbers of heat exchanger tubes.
 8. The header assembly of claim 1, wherein the header body further comprises one or more ports configured to receive at least one of a temperature sensor and a water chemistry sensor.
 9. The header assembly of claim 1, wherein the header assembly further comprises at least one of: an inlet temperature sensor configured to detect a temperature of the fluid proximate the inlet; and an outlet temperature sensor configured to detect a temperature of the fluid proximate the outlet.
 10. The header assembly of claim 1, wherein the header assembly further comprises a governor assembly configured to control a flowrate of the fluid based on a temperature of the fluid.
 11. The header assembly of claim 1, wherein the header assembly further comprises a sealing material configured to create a seal between the header and a tube sheet of the heat exchanger.
 12. A header assembly for a water heating system heat exchanger, the header assembly comprising: a header body comprising: an inlet; an outlet; an inlet compartment configured to receive a fluid from the inlet and direct the fluid to flow in a first direction; an outlet compartment configured to receive the fluid flowing from a second direction and direct the fluid to the outlet, the second direction being approximately opposite the first direction; and one or more intermediate compartments, each of the one or more intermediate compartments configured to receive the fluid flowing from the second direction and direct the fluid to flow in the first direction.
 13. The header assembly of claim 12 further comprising: a return header body comprising: two or more return compartments, each of the two or more return compartments configured to receive the fluid flowing from the first direction and direct the fluid to flow in the second direction.
 14. The header assembly of claim 13 further comprising a plurality of heat exchanger tubes fluidly connecting each of the two or more return compartments to one or more of the inlet compartment, the outlet compartment, and the one or more intermediate compartments.
 15. A heat exchanger assembly for a water heating system, the heat exchanger assembly comprising: a plurality of heat exchanger tubes, the plurality of heat exchanger tubes configured to transfer heat from a first fluid to a second fluid; a first header in fluid communication with the plurality of heat exchanger tubes, the first header comprising: an inlet; an outlet; a first header baffle configured to at least partially separate an interior of the first header into a first compartment, a second compartment, and a third compartment; and a second header in fluid communication with the plurality of heat exchanger tubes, the second header comprising: a second header baffle configured to at least partially separate an interior of the second header into a first return compartment and a second return compartment, wherein the heat exchanger assembly is configured to direct a flow of the second fluid from the inlet and sequentially through the first compartment, through a first heat exchanger tube of the plurality of heat exchanger tubes, through the first return compartment, through a second heat exchanger tube of the plurality of heat exchanger tubes, through the second compartment, through a third heat exchanger tube of the plurality of heat exchanger tubes, through the second return compartment, through a fourth heat exchanger tube of the plurality of heat exchanger tubes, and through the third compartment to the outlet.
 16. The heat exchanger assembly of claim 15, wherein the first header further comprises at least one of: an inlet temperature sensor configured to detect a temperature of the fluid proximate the inlet; and an outlet temperature sensor configured to detect a temperature of the fluid proximate the outlet.
 17. The heat exchanger assembly of claim 15, wherein: the first header baffle comprises a first removeable baffle portion and a second removeable baffle portion, the first removeable baffle portion is configured to at least partially separate the first compartment and the third compartment, and the second removeable baffle portion is configured to at least partially separate the first compartment, the second compartment, and the third compartment.
 18. The heat exchanger assembly of claim 17, wherein the first removeable baffle portion further comprises a fluid bypass mechanism configured to direct an amount of the second fluid proximate the inlet toward the outlet.
 19. The heat exchanger assembly of claim 17, wherein the first header further comprises a plurality of support ribs configured to provide support to the first removeable baffle portion and the second removeable baffle portion.
 20. The heat exchanger assembly of claim 17, wherein the second header further comprises a protrusion on an inside surface of the second header configured to direct the second fluid toward the plurality of heat exchanger tubes. 